Four-layer full-stack BMS system architecture
Plain Text │ SimCar battery HIL test bench | Cell simulator │ | Bus recorder | EOL BMS production-line test equipment │ ├─────────────────────────────────────────────────────────┤ | SOC/SOH/SOP estimation engine │ | Active/passive balancing strategy │ | HV insulation & contactor-weld detection logic │ | Charge/discharge power limiting │ | Thermal management linkage control │ | UDS diagnostic protocol stack | Graded fault protection │ | Daisy-chain/CAN communication protocols │ ├─────────────────────────────────────────────────────────┤ | CSC cell monitoring module │ | CVS high-voltage acquisition board │ | Multi-channel daisy-chain communication interfaces │ | High-precision voltage/temperature acquisition channels │ | HV relay drivers, insulation detection hardware, wide-temperature automotive-grade design |├─────────────────────────────────────────────────────────┤ | Safe charge/discharge control │ | Cell balancing control │ | HV power up/down & precharge management │ | Cross-domain coordination with VCU/thermal management │ | Battery fault diagnostics, warning, and graded protection |└───────────────────────────────────────────────────────────────┘ |
System interconnection logic
Individual cells / high-voltage circuit sensors → CSC acquisition module (daisy-chain upload) → BMU main control unit. The BMS communicates with the vehicle central domain / VCU via CAN and interfaces with the SimCar battery HIL simulation bench; upper-computer tools complete the full closed loop of modeling, code generation, calibration and automated testing.
1. High-precision multi-dimensional battery status monitoring
The CSC acquisition module achieves synchronized multi-channel cell voltage and temperature sampling, and together with the CVS high-voltage acquisition unit accurately measures total voltage, charge/discharge current and insulation resistance. With low sampling error, it captures cell voltage and temperature differences in real time.
2. High-precision SOC/SOH/SOP estimation algorithms
Fusing ampere-hour integration, open-circuit voltage correction and temperature compensation, SOC estimation error is kept within 5%. It supports SOH aging assessment and dynamic SOP peak charge/discharge power limiting to avoid battery damage from over-charging and over-discharging.
3. Dual-mode battery balancing control
Supporting both passive resistor balancing and active energy-transfer balancing, it automatically matches the balancing strategy to battery capacity and usage scenario, quickly narrowing cell voltage differences and extending battery pack cycle life.
4. Full-chain high-voltage safety management
Integrated with pre-charge logic, high-voltage relay welding detection, insulation fault diagnostics and collision-induced high-voltage power-down protection, its tiered fault handling logic quickly cuts off the high-voltage circuit on over-voltage, under-temperature, over-current or insulation failure, safeguarding vehicle safety.
5. Cross-domain coordination and standardized communication
It interacts in real time with the vehicle VCU and thermal management controller via CAN FD, coordinating cooling and heating strategies; supports daisy-chain acquisition and J1939/UDS diagnostic protocols, automatically generates A2L calibration files, and is compatible with mainstream calibration tools such as INCA and MeCa.
6. Dedicated battery HIL full-scenario simulation
The SimCar battery cell simulator and high-voltage fault injection box simulate extreme conditions such as cell short circuits, wire breaks, insulation failures and high/low temperatures, automatically executing tens of thousands of charge/discharge test cases and greatly reducing real-pack test risks.
1. Same-source software and hardware, greatly shortening development cycles.
Prototyping and mass-production BMS hardware are fully interchangeable; ECUCoder generates vehicle-level BMS code with one click, eliminating manual low-level driver development. The development cycle is shortened by 50% compared with traditional approaches.
2. Fully self-controlled toolchain with no foreign tool lock-in.
Modeling, code generation, HIL simulation and calibration software are all developed in-house, with fully open low-level code and support for domestic MCU chips — no expensive overseas licensing fees.
3. Distributed architecture adaptable to all battery packs.
The modular BMU+CSC design flexibly scales the number of cell strings, suiting small-capacity passenger-vehicle batteries and large-capacity commercial-vehicle energy storage batteries. Hardware can be flexibly trimmed for both small/medium and large batch production.
4. Complete high-voltage safety system meeting functional safety.
With comprehensive FMEA analysis and fault-injection simulation capability, it meets ISO 26262 functional safety requirements, covering the full safety flow of low-voltage wake-up, pre-charge and collision power-down, and passes stringent DV/PV automotive-grade tests.
5. Full-lifecycle battery data traceability.
Driving charge/discharge data and fault logs can be stored; production-line EOL equipment performs fully automated off-line calibration, flashing and functional testing of the BMS, and production data can interface with MES systems.
6. Wide multi-scenario adaptability.
Covering battery-electric passenger vehicles, hybrid models, fuel-cell support battery systems, heavy-truck energy storage, construction machinery battery packs and stationary energy storage stations, with strong universality.